8ZR-FXE ENGINE MECHANICAL  ENGINE UNIT  REASSEMBLY  

3.031,2.469 3.344,2.625 0.313,0.156 10 false *a 0.719,2.125 1.031,2.281 0.313,0.156 10 false *b 1.354,2.75 1.667,2.906 0.313,0.156 10 false *c

*a	Protrusion Height
*b	11 mm
*c	8.0 mm

Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly.

Standard Ring Pin:

Item	Protrusion Height	Height	Width
Ring pin	4.0 mm (0.157 in.)	8.0 mm (0.315 in.)	11 mm (0.433 in.)

0.656,2.677 0.813,2.875 0.156,0.198 10 false A

Apply seal packing as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard Seal Packing Diameter:

Area	Specified Condition
Continuous Line	2.0 to 3.0 mm (0.0787 to 0.118 in.)
(A)	4.5 to 5.5 mm (0.177 to 0.217 in.)

Application Length (A):

56 mm (2.20 in.)

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the stiffening crankcase assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installing the stiffening crankcase assembly.

3.135,0.719 3.292,0.917 0.156,0.198 10 false A 3.135,1.573 3.292,1.771 0.156,0.198 10 false A 0.896,0.125 1.052,0.323 0.156,0.198 10 false B 1.406,0.115 1.563,0.313 0.156,0.198 10 false B 1.708,0.167 1.865,0.365 0.156,0.198 10 false B 2.188,0.25 2.344,0.448 0.156,0.198 10 false C 0.719,2.198 0.875,2.396 0.156,0.198 10 false C 1.073,2.177 1.229,2.375 0.156,0.198 10 false C 1.417,2.188 1.573,2.385 0.156,0.198 10 false C 1.844,2.135 2,2.333 0.156,0.198 10 false C 2.354,2.135 2.51,2.333 0.156,0.198 10 false C 0.896,2.448 1.052,2.646 0.156,0.198 10 false 8 1.406,2.438 1.563,2.635 0.156,0.198 10 false 4 1.708,2.49 1.865,2.688 0.156,0.198 10 false 2 2.198,2.552 2.354,2.75 0.156,0.198 10 false 6 3.135,3.052 3.292,3.25 0.156,0.198 10 false 9 3.115,3.906 3.333,4.156 0.219,0.25 10 false 11 2.365,4.469 2.521,4.667 0.156,0.198 10 false 7 1.865,4.469 2.021,4.667 0.156,0.198 10 false 3 1.323,4.469 1.479,4.667 0.156,0.198 10 false 1 1.042,4.469 1.198,4.667 0.156,0.198 10 false 5 0.563,4.417 0.781,4.667 0.219,0.25 10 false 10

Install the stiffening crankcase assembly with the 11 bolts in the order shown in the illustration.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Bolt Length:

Item	Specified Condition
Bolt (A)	138 mm (5.43 in.)
Bolt (B)	35 mm (1.38 in.)
Bolt (C)	70 mm (2.76 in.)

2.927,2.448 3.24,2.604 0.313,0.156 10 false *a 0.646,2.135 0.958,2.292 0.313,0.156 10 false *b 1.25,2.74 1.563,2.896 0.313,0.156 10 false *c

*a	Protrusion Height
*b	11 mm
*c	8.0 mm

Using a plastic hammer, tap 2 new ring pins into the stiffening crankcase assembly.

Standard Ring Pin:

Item	Protrusion Height	Height	Width
Ring pin	3.0 mm (0.118 in.)	8.0 mm (0.315 in.)	11 mm (0.433 in.)

1.625,2.552 1.938,2.708 0.313,0.156 10 false *a 2.281,2.729 2.594,2.885 0.313,0.156 10 false *b 1.635,2.906 1.948,3.063 0.313,0.156 10 false *a

*a	9 mm (0.354 in.)
*b	19 mm (0.748 in.)

Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

2.75,2.073 2.552,1.781 true 0.271,1.344 0.427,1.542 0.156,0.198 10 false A 0.906,1.344 1.063,1.542 0.156,0.198 10 true A 0.292,0.938 0.448,1.135 0.156,0.198 10 false B 0.906,0.938 1.073,1.104 0.167,0.167 10 true B 1.021,2.354 1.792,2.552 0.771,0.198 10 false A - A 2.177,2.354 2.948,2.552 0.771,0.198 10 false B - B 2.74,2.125 3.052,2.323 0.313,0.198 10 false *a 0.729,2.573 1.042,2.771 0.313,0.198 10 false *b 2.604,2.542 2.917,2.74 0.313,0.198 10 false *c

*a	Seal Packing
*b	6.0 mm
*c	3.0 to 4.5 mm

Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Application Specification:

Area	Seal Packing Diameter	Distance from Center of Bolt Hole to Center of Seal Packing
(A) - (A)	3.0 to 4.5 mm (0.118 to 0.177 in.)	6.0 mm (0.236 in.)
(B) - (B)		-

2.177,1.802 2.49,1.958 0.313,0.156 10 false *a 0.208,1.656 0.521,1.813 0.313,0.156 10 false *a

*a

Nut

Install the No. 2 oil pan sub-assembly to the stiffening crankcase assembly with the 10 bolts and 2 nuts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Install a new gasket and oil pan drain plug to the No. 2 oil pan sub-assembly.

Torque:

37 N*m (377 kgf*cm, 27 ft.*lbf)

0,0 0,0 false

Front of Engine

Install the 2 cylinder block water jacket spacers to the cylinder block sub-assembly as shown in the illustration.

NOTICE:

Make sure that the water jacket spacer does not stick out from the top surface of the cylinder block sub-assembly.

Step 1:

i.

0.708,1.813 0.958,2.042 0.25,0.229 10 true 10 0.698,0.271 0.854,0.469 0.156,0.198 10 true 8 1.177,0.271 1.333,0.469 0.156,0.198 10 true 4 1.188,1.802 1.344,2 0.156,0.198 10 true 6 1.677,0.281 1.833,0.479 0.156,0.198 10 true 2 1.646,1.802 1.896,2.042 0.25,0.24 10 true 1 2.146,0.26 2.302,0.458 0.156,0.198 10 true 5 2.146,1.802 2.302,2 0.156,0.198 10 true 3 2.646,0.26 2.802,0.458 0.156,0.198 10 true 9 2.635,1.781 2.792,1.979 0.156,0.198 10 true 7

Using a 10 mm bi-hexagon socket wrench, install and uniformly tighten the 10 cylinder head set bolts in several steps in the order shown in the illustration.

Torque:

49 N*m (500 kgf*cm, 36 ft.*lbf)

NOTICE:

Do not drop the cylinder head set plate washers for the cylinder head set bolts into the cylinder head sub-assembly.

1.49,1.531 1.635,1.531 1.635,1.531 1.906,1.115 true 1.458,0.396 1.771,0.594 0.313,0.198 10 false 90° 2.542,0.125 2.854,0.323 0.313,0.198 10 false 45° 1.281,1.469 1.594,1.667 0.313,0.198 10 false *a

*a	Paint Mark
	Front of Engine

Step 2:

0.677,2.177 0.99,2.333 0.313,0.156 10 false *a 2.313,2.177 2.625,2.333 0.313,0.156 10 false *b

*a	Before Wiping Off
*b	After Wiping Off

After tightening the cylinder head set bolts, wipe off any seal packing that seeped out from the contact surfaces between the cylinder head sub-assembly and cylinder block sub-assembly.

NOTICE:

·

Be sure to wipe off the seal packing from inside to outside, parallel to the joint line.

·

Be sure to avoid clogging the bolt holes when wiping off the seal packing.

Install the 16 valve stem caps to the cylinder head sub-assembly.

NOTICE:

·

Install each part to its original location.

·

Do not drop the valve stem caps into the cylinder head sub-assembly.

Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

NOTICE:

Install each part to its original location.

0.719,1.313 1.146,1.313 false 1.208,0.396 1.635,0.396 false 2.156,0.729 2.583,0.729 false 0.531,1.229 0.844,1.427 0.313,0.198 10 false *1 1.021,0.313 1.333,0.51 0.313,0.198 10 false *2 2.646,0.656 2.958,0.854 0.313,0.198 10 false *3

*1	Valve Lash Adjuster Assembly
*2	No. 1 Valve Rocker Arm Sub-assembly
*3	Valve Stem Cap

Apply engine oil to the tips of the valve lash adjuster assemblies and valve stem caps.

3.052,2.458 3.365,2.615 0.313,0.156 10 false *a 0.719,2.146 1.031,2.302 0.313,0.156 10 false *b 1.344,2.74 1.656,2.896 0.313,0.156 10 false *c

*a	Protrusion Height
*b	20 mm
*c	13 mm

Using a plastic hammer, tap 10 new ring pins into the camshaft housing sub-assembly.

Standard Ring Pin:

Item	Protrusion Height	Height	Width
Ring pin	3.0 mm (0.118 in.)	13 mm (0.512 in.)	20 mm (0.787 in.)

0.448,2.938 0.448,2.135 0.448,2.135 0.615,2.135 false 0.542,2.635 0.698,2.833 0.156,0.198 10 false A 2.396,2.646 2.552,2.844 0.156,0.198 10 true B 0.677,2.031 0.99,2.229 0.313,0.198 10 false *a

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the No. 1 camshaft bearing cap edge and the No. 1 camshaft bearing edge.

Standard Dimension (A) - (B):

0.7 mm (0.0276 in.) or less

NOTICE:

Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions (A) and (B).

1.26,4.083 1.26,3.781 false 1.281,3.281 1.438,3.479 0.156,0.198 10 false A 1.188,4.104 1.5,4.302 0.313,0.198 10 false *a

*a	Vernier Caliper

Using a vernier caliper, measure the distance between the camshaft housing sub-assembly edge and the No. 2 camshaft bearing edge.

Dimension (A):

1.05 to 1.75 mm (0.0413 to 0.0689 in.)

NOTICE:

Position the No. 2 camshaft bearings to the center of the camshaft housing sub-assembly by measuring dimension (A).

Check that no foreign matter is on the mesh of the oil control valve filter.

Install the camshaft to the camshaft housing sub-assembly.

0.979,2.542 1.271,2.292 1.271,2.292 1.396,2.292 false 2.448,2.542 2.448,2.198 2.448,2.198 2.604,2.198 false 1.469,2.208 1.781,2.365 0.313,0.156 10 false *a 2.74,2.458 3.198,2.656 0.458,0.198 10 false 50° 2.656,2.115 2.969,2.271 0.313,0.156 10 false *a

*a

Knock Pin

Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

0.229,0.458 0.542,0.656 0.313,0.198 10 false 10 0.229,1.521 0.385,1.719 0.156,0.198 10 false 9 0.771,0.344 0.927,0.542 0.156,0.198 10 true 6 0.719,1.563 0.875,1.76 0.156,0.198 10 true 5 1.292,0.354 1.448,0.552 0.156,0.198 10 true 2 1.917,1.583 2.073,1.781 0.156,0.198 10 true 1 2.448,0.521 2.604,0.719 0.156,0.198 10 true 4 2.427,1.531 2.583,1.729 0.156,0.198 10 true 3 2.938,0.531 3.094,0.729 0.156,0.198 10 true 8 2.896,1.594 3.052,1.792 0.156,0.198 10 true 7

Tighten the 10 bearing cap bolts in the order shown in the illustration.

Torque:

16 N*m (163 kgf*cm, 12 ft.*lbf)

0.448,0.813 0.656,0.813 false 1.177,1.469 1.344,1.469 false 2.854,1.49 3.021,1.49 false 1.125,0.677 1.292,0.677 false 2.167,0.76 2.375,0.76 false 2.927,0.656 3.135,0.656 false 1.333,0.594 1.646,0.792 0.313,0.198 10 false *1 3.167,0.563 3.375,0.781 0.208,0.219 10 false *1 1.406,1.365 1.719,1.563 0.313,0.198 10 false *2 3.083,1.427 3.396,1.625 0.313,0.198 10 false *2 1.99,0.667 2.302,0.865 0.313,0.198 10 false *3 0.281,0.719 0.594,0.917 0.313,0.198 10 false *3 0.833,0.167 1.146,0.365 0.313,0.198 10 false *a 2.75,0.177 3.063,0.375 0.313,0.198 10 false *b

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap
*a	Correct
*b	Incorrect

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

1.396,1.052 1.813,0.635 true 1.677,2.813 1.469,2.396 true 0.271,0.458 0.583,0.615 0.313,0.156 10 false *a 1.802,0.479 2.115,0.635 0.313,0.156 10 false *b 1.646,2.865 1.958,3.021 0.313,0.156 10 false *c

*a	Cylinder Head Sub-assembly Upper Side
*b	Seal Packing
*c	3.5 to 4.0 mm (0.138 to 0.157 in.)

Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

1.26,1.969 1.427,2.167 0.167,0.198 10 true 1 1.677,1.344 1.844,1.542 0.167,0.198 10 false 2 2.156,1.344 2.323,1.542 0.167,0.198 10 false 5 2.969,1.469 3.208,1.677 0.24,0.208 10 false 11 3.208,2.219 3.406,2.417 0.198,0.198 10 false 16 2.938,3.115 3.135,3.313 0.198,0.198 10 true 12 2.177,3.208 2.344,3.406 0.167,0.198 10 true 6 1.698,3.208 1.865,3.406 0.167,0.198 10 true 3 1.198,3.208 1.365,3.406 0.167,0.198 10 true 9 0.302,3.167 0.521,3.406 0.219,0.24 10 false 15 0.125,2.302 0.323,2.5 0.198,0.198 10 false 13 0.208,1.427 0.427,1.625 0.219,0.198 10 false 14 0.76,1.948 0.927,2.146 0.167,0.198 10 true 7 1.75,1.948 1.917,2.146 0.167,0.198 10 true 4 2.188,1.99 2.385,2.188 0.198,0.198 10 true 10 1.177,1.323 1.344,1.521 0.167,0.198 10 false 8 0.75,1.219 0.99,1.427 0.24,0.208 10 false 17

	Bolt (A)
	Bolt (B)

Set the camshaft and No. 2 camshaft as shown in the illustration.

Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt.

Torque:

54 N*m (551 kgf*cm, 40 ft.*lbf)

2.167,0.948 2.458,1.615 true 1.052,0.885 1.677,0.406 true 2.438,1.635 2.75,1.792 0.313,0.156 10 false *a 1.719,0.333 2.031,0.49 0.313,0.156 10 false *b

*a	Knock Pin
*b	Knock Pin Hole

Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

1.104,2.292 0.615,1.854 0.615,1.854 1.083,1.49 false 1.427,2.438 2.313,1.698 2.313,1.698 1.417,1.344 false 0.417,1.792 0.729,1.948 0.313,0.156 10 false *1 2.375,1.615 2.688,1.771 0.313,0.156 10 false *a 1.313,1.781 1.625,1.938 0.313,0.156 10 false *b

*1	Camshaft Timing Gear Assembly
*a	Camshaft Flange
*b	No Gap

Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

Using a wrench to hold the hexagonal portion of the camshaft, tighten the bolt.

Torque:

54 N*m (551 kgf*cm, 40 ft.*lbf)

0,0 0,0 false

Lock

Check that the camshaft timing gear assembly can move in the retard direction (clockwise) and locks in the most retarded position.

Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

HINT:

Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

Install the No. 1 crankshaft position sensor plate to the crankshaft with the "F" mark facing forward.

2.708,0.74 2.844,0.583 true 2.583,0.76 2.896,0.958 0.313,0.198 10 true *1

*1	Crankshaft Timing Gear Key

Set the crankshaft timing gear keys as shown in the illustration.

2.146,1.698 1.948,1.698 1.948,1.698 1.365,1.792 false 2.146,2.177 1.979,2.177 1.979,2.177 1.302,1.938 false 2.26,2.792 2.094,2.792 2.094,2.792 1.417,2.552 false 2.656,3.271 2.49,3.271 2.49,3.271 1.792,3.604 false 2.667,3.875 2.5,3.875 2.5,3.875 1.802,4.208 false 2.656,4.49 2.5,4.49 2.5,4.49 1.802,4.375 false 2.219,1.625 2.531,1.823 0.313,0.198 10 false *a 2.208,2.104 2.521,2.302 0.313,0.198 10 false *b 2.333,2.708 2.646,2.906 0.313,0.198 10 false *1 2.719,3.198 3.031,3.396 0.313,0.198 10 false *2 2.74,3.813 3.052,4.01 0.313,0.198 10 false *b 2.719,4.417 3.031,4.615 0.313,0.198 10 false *a

*1	Oil Pump Drive Gear
*2	Oil Pump Drive Shaft Gear
*a	Mark Plate (Yellow)
*b	Timing Mark
	Front of Engine

Align the mark plates (yellow) with the timing mark of the oil pump drive gear and oil pump drive shaft gear as shown in the illustration.

HINT:

Make sure the mark plates (yellow) of the No. 2 chain sub-assembly are facing away from the engine assembly.

0.573,1.438 1.229,1.438 false 1.042,1.198 1.698,1.198 true 0.354,1.385 0.667,1.542 0.313,0.156 10 false *1 0.844,1.135 1.156,1.292 0.313,0.156 10 false *2

*1	Chain Tensioner Plate
*2	Chain Damper Spring

Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate with the bolt.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

0.938,1.021 0.469,1.542 0.469,1.542 1.771,1.573 true 0.49,1.531 1.156,1.396 true 0.177,1.49 0.635,1.688 0.458,0.198 10 false SST

Using SST, hold the crankshaft pulley and tighten the oil pump drive shaft gear nut.

SST

09213-58014  (91551-80840)
09330-00021  

Torque:

28 N*m (286 kgf*cm, 21 ft.*lbf)

Install the crankshaft timing sprocket to the crankshaft.

1.792,0.958 2.396,0.958 true 2.458,0.896 2.771,1.052 0.313,0.156 10 true *1

*1	Crankshaft Timing Gear Key

Turn the crankshaft clockwise until the crankshaft timing gear key is facing upward.

1.563,1.292 2.198,0.604 true 0.521,1.229 1.177,0.427 true 0.313,1.458 0.313,1.708 0.313,1.708 0.906,1.708 true 0.781,1.427 0.781,1.698 true 2.229,0.479 2.542,0.635 0.313,0.156 10 false *a 1.208,0.281 1.521,0.438 0.313,0.156 10 false *b 0.938,1.635 1.25,1.792 0.313,0.156 10 true *c

*a	Timing Mark
*b	Timing Mark (Rectangle)
*c	Mark (Circle)

Check that the timing marks on the camshaft timing gear assembly and camshaft timing sprocket are aligned as shown in the illustration.

HINT:

There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

Install the No. 2 chain vibration damper to the camshaft housing sub-assembly with the 2 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the chain tensioner slipper to the cylinder block sub-assembly.

Using a 10 mm hexagon socket wrench, install 2 new gaskets and the 2 oil filter bracket with head straight screw plugs to the oil filter bracket.

Torque:

44 N*m (449 kgf*cm, 32 ft.*lbf)

Type A:

i.

1.938,2.594 2.25,2.75 0.313,0.156 10 false *a 1.948,3.125 2.26,3.281 0.313,0.156 10 false *b 2.385,2.833 2.698,2.99 0.313,0.156 10 false *c

*a	21 mm (0.827 in.)
*b	9 mm (0.354 in.)
*c	34 mm (1.34 in.)

Using an E6 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

Install the 2 stud bolts as shown in the illustration.

Torque:

5.0 N*m (51 kgf*cm, 44 in.*lbf)

Install a new gasket to the engine water pump assembly.

HINT:

Be sure to clean the contact surfaces.

Install the engine water pump assembly to the timing chain cover sub-assembly with the 3 bolts.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Clean the contact surfaces of the timing chain cover sub-assembly, camshaft housing sub-assembly, cylinder head sub-assembly, cylinder block sub-assembly and stiffening crankcase assembly, and confirm that no oil, moisture, or other foreign matter is on the surfaces.

1.167,0.333 1.479,0.49 0.313,0.156 10 false *a 4.323,0.365 4.635,0.521 0.313,0.156 10 false *b

*a	Cylinder Head Sub-assembly and Cylinder Block Sub-assembly Side	*b	Timing Chain Cover Sub-assembly Side
	Clean and degrease	-	-

Install 3 new O-rings to the cylinder head sub-assembly and cylinder block sub-assembly.

Apply seal packing to the engine unit as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal Packing Diameter:

5.0 mm (0.197 in.)

NOTICE:

Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

Apply seal packing to the timing chain cover sub-assembly in a continuous line as shown in the illustration.

2.292,2.177 2.781,1.906 true 4.604,1.958 5.031,2.26 true 1.583,5.479 1.833,5.865 true 3.615,5.438 4.01,5.74 true 5.604,5.49 6,5.792 true 2.323,1.146 2.479,1.344 0.156,0.198 10 false A 3.052,0.802 3.208,1 0.156,0.198 10 true A 1.875,1.427 2.031,1.625 0.156,0.198 10 false F 1.521,2.031 1.677,2.229 0.156,0.198 10 false G 1.146,2.292 1.302,2.49 0.156,0.198 10 false H 2.146,2.167 2.302,2.365 0.156,0.198 10 false D 2.427,2.344 2.583,2.542 0.156,0.198 10 false O 5.01,1.333 5.167,1.531 0.156,0.198 10 false J 5.083,2.271 5.24,2.469 0.156,0.198 10 false E 5.375,2 5.531,2.198 0.156,0.198 10 false K 5.74,2.229 5.896,2.427 0.156,0.198 10 false L 6.094,2.271 6.25,2.469 0.156,0.198 10 false M 6.469,4.063 6.625,4.26 0.156,0.198 10 false N 0.75,4.031 0.906,4.229 0.156,0.198 10 false I 1.521,5.063 1.833,5.219 0.313,0.156 10 false *a 3.49,5.01 3.802,5.167 0.313,0.156 10 false *b 5.448,5.042 5.76,5.198 0.313,0.156 10 false *c 6.042,5.75 6.354,5.906 0.313,0.156 10 false *f 4.052,5.708 4.365,5.865 0.313,0.156 10 false *e 1.885,5.833 2.198,5.99 0.313,0.156 10 false *d 1.219,6.583 1.375,6.781 0.156,0.198 10 false D 4.688,6.552 4.844,6.75 0.156,0.198 10 false E 1.646,7.594 1.802,7.792 0.156,0.198 10 false B 2.417,7.146 2.573,7.344 0.156,0.198 10 false B 5.083,7.323 5.24,7.521 0.156,0.198 10 false B 5.854,7.594 6.01,7.792 0.156,0.198 10 false B 4.906,8.292 5.063,8.49 0.156,0.198 10 false B 5.615,8.667 5.771,8.865 0.156,0.198 10 false B 5.167,7.99 5.323,8.188 0.156,0.198 10 false C 5.854,8.073 6.01,8.271 0.156,0.198 10 false C 1.646,8.021 1.802,8.219 0.156,0.198 10 false C 2.427,8.01 2.583,8.208 0.156,0.198 10 false C 1.375,4.833 2.146,5.031 0.771,0.198 10 false A - A 3.417,4.844 4.188,5.042 0.771,0.198 10 false B - B 5.385,4.813 6.156,5.01 0.771,0.198 10 false C - C

*a	2.5 mm	*b	5.0 mm
*c	7.5 mm	*d	2.5 to 3.5 mm
*e	4.5 to 5.5 mm	*f	7.0 to 8.0 mm

Seal Packing:

Item	Seal Packing
Dashed line	Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Continuous line
Alternate long and short dashed line	Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

Application Specification:

Area	Seal Packing Diameter	Distance from Edge of Cover to:	Seal Packing Application Length	Distance from Top of Cover to Top of Seal Packing
Dashed line	2.5 to 3.5 mm (0.0984 to 0.138 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
Continuous line	4.5 to 5.5 mm (0.177 to 0.217 in.) or 7.0 to 8.0 mm (0.276 to 0.315 in.)	-	-	-
Alternate long and short dashed line	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-
(A) - (A)	2.5 to 3.5 mm (0.0984 to 0.138 in.)	Center of seal packing 2.5 mm (0.0984 in.)	-	-
(B) - (B)	4.5 to 5.5 mm (0.177 to 0.217 in.)	Opposite edge of seal packing 5.0 mm (0.197 in.)	-	-
(C) - (C)	7.0 to 8.0 mm (0.276 to 0.315 in.)	Opposite edge of seal packing 7.5 mm (0.295 in.)	-	-
(F)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	15.5 mm (0.610 in.)	50.4 mm (1.98 in.)
(G)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	10.3 mm (0.406 in.)	143.1 mm (5.63 in.)
(H)	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	19.5 mm (0.768 in.)	153.4 mm (6.04 in.)
(I)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	16.0 mm (0.630 in.)	385.8 mm (1.27 ft.)
(J)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	18.6 mm (0.732 in.)	51.4 mm (2.02 in.)
(K)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	25.3 mm (0.996 in.)	121.9 mm (4.80 in.)
(L)	7.0 to 8.0 mm (0.276 to 0.315 in.)	-	25.8 mm (1.02 in.)	147.2 mm (5.80 in.)
(M)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	5.1 mm (0.201 in.)	173.0 mm (6.81 in.)
(N)	4.5 to 5.5 mm (0.177 to 0.217 in.)	-	14.6 mm (0.575 in.)	385.8 mm (1.27 ft.)
(O)	4.0 mm (0.157 in.)	Center of seal packing 3.0 mm (0.118 in.)	-	-

NOTICE:

Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.

2.458,0.198 2.24,0.198 2.24,0.198 1.99,1.188 false 2.521,0.115 2.813,0.292 0.292,0.177 10 false *a

*a

Adhesive

Apply adhesive to 5 and a half threads or more of the end of the 2 bolts (E).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

1.531,2.521 1.531,2.25 true 1.448,2.563 1.688,2.719 0.24,0.156 10 true *1 0.156,0.583 0.313,0.781 0.156,0.198 10 false E 2.781,0.563 2.938,0.76 0.156,0.198 10 false E 0.208,0.99 0.365,1.188 0.156,0.198 10 false A 0.25,1.271 0.406,1.469 0.156,0.198 10 false B 2.604,1.313 2.76,1.51 0.156,0.198 10 false B 2.458,1.677 2.615,1.875 0.156,0.198 10 false B 2.333,1.844 2.49,2.042 0.156,0.198 10 false A 2.531,1.906 2.688,2.104 0.156,0.198 10 false D 0.354,1.729 0.51,1.927 0.156,0.198 10 false B 0.385,2.083 0.542,2.281 0.156,0.198 10 false A 0.375,2.573 0.531,2.771 0.156,0.198 10 false A 1.552,1.656 1.708,1.854 0.156,0.198 10 true C 2.396,2.583 2.552,2.781 0.156,0.198 10 true D 2.51,2.885 2.667,3.083 0.156,0.198 10 true A 0.396,3.104 0.552,3.302 0.156,0.198 10 false A 2.469,3.323 2.625,3.521 0.156,0.198 10 false A 2.365,3.771 2.521,3.969 0.156,0.198 10 false A 1.771,4.427 1.927,4.625 0.156,0.198 10 false A

*1	Seal Washer

Temporarily install the timing chain cover sub-assembly with the 18 bolts and a new seal washer.

Bolt Length:

Item	Length
Bolt (A), (E)	35 mm (1.38 in.)
Bolt (B), (D)	55 mm (2.17 in.)
Bolt (C)	40 mm (1.57 in.)

NOTICE:

Make sure that there is no oil on the threads of the bolts.

Fully tighten the 25 bolts in the order shown in the illustration.

0.802,0.052 1.115,0.208 0.313,0.156 10 false *a 4.115,0.073 4.427,0.229 0.313,0.156 10 false *b 0.698,0.802 0.854,1 0.156,0.198 10 false A 0.823,1.688 0.979,1.885 0.156,0.198 10 false A 0.823,2.094 0.979,2.292 0.156,0.198 10 false A 0.802,2.5 0.958,2.698 0.156,0.198 10 false A 0.813,2.667 0.969,2.865 0.156,0.198 10 false A 1.615,2.438 1.771,2.635 0.156,0.198 10 true A 1.625,3.333 1.781,3.531 0.156,0.198 10 true A 1.406,3.5 1.563,3.698 0.156,0.198 10 false A 1.979,3.604 2.135,3.802 0.156,0.198 10 false A 2.5,3.083 2.656,3.281 0.156,0.198 10 false A 2.583,2.698 2.74,2.896 0.156,0.198 10 false A 2.604,2.344 2.76,2.542 0.156,0.198 10 true A 2.5,2.083 2.656,2.281 0.156,0.198 10 true D 2.76,1.813 2.917,2.01 0.156,0.198 10 true D 1.781,1.313 1.938,1.51 0.156,0.198 10 true C 1.948,0.479 2.104,0.677 0.156,0.198 10 true F 2.521,1.656 2.677,1.854 0.156,0.198 10 false A 2.552,1.292 2.708,1.49 0.156,0.198 10 true B 2.698,1.073 2.854,1.271 0.156,0.198 10 true B 2.833,0.458 2.99,0.656 0.156,0.198 10 false E 0.656,0.5 0.813,0.698 0.156,0.198 10 false E 0.719,1.031 0.875,1.229 0.156,0.198 10 false B 0.802,1.396 0.958,1.594 0.156,0.198 10 false B 2.75,0.813 2.99,1.042 0.24,0.229 10 false F 5.906,1.292 6.063,1.49 0.156,0.198 10 false 1 4.125,1.396 4.281,1.594 0.156,0.198 10 false 2 6.063,1.063 6.219,1.26 0.156,0.198 10 false 3 4.021,1.031 4.177,1.229 0.156,0.198 10 false 4 6.146,0.427 6.302,0.625 0.156,0.198 10 false 5 5.833,1.656 6.052,1.938 0.219,0.281 10 false 6 6.083,1.823 6.24,2.021 0.156,0.198 10 true 7 5.802,2.094 5.958,2.292 0.156,0.198 10 true 8 5.906,2.333 6.063,2.531 0.156,0.198 10 true 9 5.865,2.719 6.177,2.917 0.313,0.198 10 false 10 5.781,3.083 6.094,3.281 0.313,0.198 10 false 11 5.26,3.604 5.573,3.802 0.313,0.198 10 false 12 4.052,2.5 4.365,2.698 0.313,0.198 10 false 13 4.052,2.083 4.365,2.281 0.313,0.198 10 false 14 4.083,1.667 4.396,1.865 0.313,0.198 10 false 15 3.938,0.781 4.25,0.979 0.313,0.198 10 false 16 3.885,0.49 4.198,0.688 0.313,0.198 10 false 17 5.031,1.281 5.344,1.479 0.313,0.198 10 true 18 6.052,0.802 6.365,1 0.313,0.198 10 false 19 5.208,0.49 5.521,0.688 0.313,0.198 10 true 20 5.865,1.49 6.177,1.688 0.313,0.198 10 false 21 4.063,2.698 4.375,2.896 0.313,0.198 10 false 22 4.688,3.51 5,3.708 0.313,0.198 10 false 23 4.896,2.375 5.208,2.573 0.313,0.198 10 true 24 4.875,3.333 5.188,3.531 0.313,0.198 10 true 25 2.531,1.49 2.688,1.688 0.156,0.198 10 false F

*a

Torque

*b

Bolt Tightening Order

Torque:

Bolt (A), (D), (E) : 25.5 N*m (260 kgf*cm, 19 ft.*lbf)

Bolt (B), (F) : 51 N*m (520 kgf*cm, 38 ft.*lbf)

Bolt (C) : 10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE:

·

Tighten the bolts within 10 minutes of applying seal packing.

·

Do not add engine oil for at least 2 hours after installation.

·

Do not start the engine for at least 2 hours after installation.

0.188,0.156 3.229,1.323 3.042,1.167 0.719,0.292 0.833,0.292 0.833,0.292 1.042,0.448 false 2.313,0.281 2.427,0.281 2.427,0.281 2.635,0.438 false 0.906,2.698 1.021,3.146 1.021,3.146 0.865,3.146 false 1.115,2.594 1.229,2.979 1.229,2.979 1.354,2.979 false 2.083,3.563 2.198,3.948 2.198,3.948 2.323,3.948 false 1.042,4.042 1.146,4.354 1.146,4.354 1.26,4.354 false 0.833,3.49 0.948,3.49 0.948,3.49 1.042,3.646 false 1.021,2.26 1.938,2.74 1.938,2.74 2.198,3.052 true 1.573,1.313 1.573,0.167 false 0.823,2.792 0.5,3.198 0.5,3.198 0.385,3.198 false 0.25,0.198 0.563,0.396 0.313,0.198 10 false *e 0.531,0.219 0.844,0.417 0.313,0.198 10 false *a 0.354,0.698 0.667,0.896 0.313,0.198 10 false *g 2.115,0.198 2.427,0.396 0.313,0.198 10 false *a 1.885,0.719 2.198,0.917 0.313,0.198 10 false *g 1.646,0.208 1.958,0.406 0.313,0.198 10 false *f 0.51,2.167 0.823,2.365 0.313,0.198 10 false *h 0.313,2.49 0.625,2.688 0.313,0.198 10 false *g 0.688,3.073 1,3.271 0.313,0.198 10 false *c 1.417,2.917 1.729,3.115 0.313,0.198 10 false *b 1.927,2.604 2.24,2.802 0.313,0.198 10 false *a 2.396,3.896 2.708,4.094 0.313,0.198 10 false *c 1.313,4.313 1.573,4.51 0.26,0.198 10 true *b 0.583,3.406 0.802,3.594 0.219,0.188 10 true *a 0.229,3.125 0.542,3.323 0.313,0.198 10 false *d

*a	Cam
*b	Hook
*c	Plunger
*d	Pin
*e	Correct
*f	Incorrect
*g	Push
*h	Raise

Raise the cam, then fully push in the plunger and engage the hook with the pin so that the plunger is in the position shown in the illustration.

NOTICE:

Make sure that the cam engages with the first tooth of the plunger to allow the hook to pass over the pin.

Install a new gasket, the bracket and No. 1 chain tensioner assembly to the timing chain cover sub-assembly with the 2 nuts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

NOTICE:

If the hook releases the plunger while the No. 1 chain tensioner assembly is being installed, set the hook again.

0.438,2.208 0.74,2.208 false 0.25,2.146 0.563,2.302 0.313,0.156 10 false *a 0.729,1.771 1.042,1.927 0.313,0.156 10 false *b

*a	Hook
*b	Release

Rotate the crankshaft counterclockwise slightly and check that the hook is released.

0.844,2.323 1.021,2.125 false 1.042,2.031 1.354,2.188 0.313,0.156 10 false *a 0.563,2.635 0.875,2.792 0.313,0.156 10 false *b

*a	Plunger
*b	Plunger is extended

Turn the crankshaft clockwise and check that the plunger is extended.

Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

1.719,2.375 1.938,2.24 false 1.76,2.948 1.958,3.104 false 1.979,2.167 2.292,2.323 0.313,0.156 10 false *1 2,3.083 2.313,3.24 0.313,0.156 10 false *2

*1	Cylinder Head Cover Sub-assembly
*2	Cylinder Head Cover Gasket

Install 3 new cylinder head cover gaskets to the cylinder head cover sub-assembly.

NOTICE:

·

Remove any oil from the contact surfaces.

·

Misalignment between the center of the cylinder head cover sub-assembly rib and the center of the cylinder head gasket tab should be 4.0 mm (0.157 in.) or less.

Install 2 new gaskets as shown in the illustration.

Apply seal packing as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard Diameter:

4.0 mm (0.157 in.)

NOTICE:

·

Remove any oil from the contact surfaces.

·

Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

·

Do not start the engine for at least 2 hours after installation.

Install the cylinder head cover sub-assembly with the 16 bolts.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

NOTICE:

2.24,1.573 2.5,1.417 true 0.917,1.854 1.979,1.854 true 1.667,1.906 1.979,2.063 0.313,0.156 10 false *1 2.375,1.917 2.688,2.073 0.313,0.156 10 false *2 2.552,1.344 2.865,1.5 0.313,0.156 10 false *3 0.688,1.781 1,1.938 0.313,0.156 10 false *a

*1	Timing Chain Cover Sub-assembly
*2	Camshaft Housing Sub-assembly
*3	Cylinder Head Cover Gasket
*a	Projection

Misalignment between the contact surfaces of the timing chain cover sub-assembly and camshaft housing sub-assembly and the center of the cylinder head cover gasket tab should be 4.0 mm (0.157 in.) or less.

Install the oil filler cap gasket to the oil filler cap sub-assembly.

Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.